In the world of precision manufacturing, mechanical processing has undergone a silent yet profound revolution. From manual operation to numerical control automation, from experience-driven to data-driven, Dongguan Zhongchuangxing Precision Machinery Manufacturing Co., Ltd. has witnessed this transformation and has always been at the forefront of technology.

CNC technology: Not just automated machine tools

The evolutionary history of numerical control systems

The first generation: Basic Numerical Control (1990s

It can only perform simple linear and circular interpolation

Programming is complex and requires specialized knowledge of G-code

The accuracy is approximately ±0.05mm

The second generation: Computer Numerical Control (2000s)

Introduce CAD/CAM integration

Realize three-dimensional processing capabilities

The accuracy has been improved to ±0.01mm

The third generation: Intelligent Numerical Control (2010s to present)

It has adaptive control capability

Real-time monitoring and compensation system

The accuracy reaches ±0.002mm

The current configuration of Zhongchuangxing: The latest systems from Fanuc of Japan and Siemens of Germany

Our device matrix: Precise configuration for different needs

Vertical machining center series

High-speed precision processing type (5 units

Spindle speed: 24,000rpm

Fast movement: 48m/min

Positioning accuracy: ±0.003mm

Applicable to: precision molds, medical parts

Heavy-duty cutting type (8 units

Spindle torque: 120Nm

Power: 22kW

Applicable to: large cavities, structural components

Advantages of horizontal machining centers

Four-axis linkage capability

Multi-faceted processing can be completed in one clamping

Reduce repetitive positioning errors

Automated integration

Equipped with dual workbenches

Automatic exchange time: 12 seconds

Realize 24-hour uninterrupted production

Five-axis linkage machining center (our technological high ground)

Technical parameters

Rotation axis accuracy: ±3 arcseconds

Swing range: ±110°

Minimum resolution: 0.0001°

Application field

Aeroengine blades

Complex curved surfaces of medical devices

Optical mold

In-depth practice of technological innovation

Breakthrough in the processing technology of thin-walled parts

Technical difficulties

Wall thickness is less than 0.3mm

Height over 50mm

Material: Aluminum alloy/titanium alloy

Our solution

Process route

Rough machining (with a allowance of 0.5mm) → aging treatment to relieve stress →

Semi-finishing (with a allowance of 0.1mm) → secondary aging →

Finishing (layer-by-layer cutting, 0.02mm per layer)

Control of key parameters

Cutting speed: Dynamically adjusted according to the material

Feed rate: Adopt a variable feed strategy

Cooling method: High-pressure internal cooling (pressure 8MPa)

"Outcome

Deformation control: < 0.05mm

Surface roughness: Ra0.4μm

Yield rate: 98.7%

2. Technological exploration of deep hole processing

Challenge

Aperture: Φ0.5-Φ3mm

Depth-to-diameter ratio: above 20:1

Precision requirement: IT6 grade

Technological innovation

Special tool design

Internal cooling channel optimization

Tool coating: TiAlN+ diamond composite coating

The chip removal trough is specially designed

Process strategy

Pecking and drilling combined with helical interpolation

Chip removal is carried out by retreating 0.5mm per drill

Real-time monitoring of torque changes

Online compensation system

Laser probe aperture monitoring

Automatically compensate for tool wear

Temperature compensation algorithm

3. Expertise in processing special materials

Processing of stainless steel series

Problem: Severe work hardening and short tool life

Our plan

Tool selection: Ultrafine-grained cemented carbide

Cutting parameters

Linear speed: 60-80m/min

Feed per tooth: 0.05-0.08mm

Cutting depth: 0.5-2mm

Coolant: Extreme pressure emulsion

Processing of superalloys

Take Inconel 718 as an example

Traditional problem: The tool life is only 10 to 15 minutes

Our breakthrough

Use ceramic cutting tools

High-speed processing (200-300m/min)

Micro-lubrication technology

The tool life has been extended to 45 minutes

The practice of intelligent manufacturing

1. Adaptive processing system

Core technology

Real-time monitoring of spindle power

Vibration sensor network

Analysis of Intelligent Algorithms

Actual effect

Automatically optimize cutting parameters

Predictive maintenance

Reduce the scrap rate by 30%

2. Application of Digital Twin Technology

Our implementation

Virtual processing simulation

Detect interference problems in advance

Optimize the processing path

Reduce the number of trial cuts

Real-time data mapping

Machine tool status monitoring

Workpiece quality prediction

Energy Consumption Optimization analysis

3. Automated production unit

Configuration

Six machining centers

Two industrial robots

Automatic detection station

AGV logistics system

Operating indicators

Equipment utilization rate: 85%

Change time: Less than 15 minutes

Per capita output value: Increase by 300%

Typical case: Manufacturing of fuel injectors for automotive engines

Technical requirements

Material: Powder metallurgy high-speed steel

Aperture: Φ0.12mm±0.002mm

Surface roughness: Ra0.1μm

Taper: 0.001mm/10mm

Technical challenges

The precision requirements for micro-hole processing are extremely high

The material has a high hardness (HRC62-64)

Consistency requirements for mass production

Solution system

Customized equipment transformation

Install ultra-precision spindles (runout < 0.001mm

Install a constant temperature oil cooling system (temperature fluctuation ±0.1℃)

Upgrade the resolution of the grating ruler (0.0001mm

Development of special cutting tools

Micro-diameter tungsten steel drill bit (Φ0.12mm)

Special cutting edge design

Nanoscale diamond coating

Technological innovation

Guide hole technology

First, process the guide hole with a Φ0.3mm drill bit

Depth: 5mm

Hierarchical processing strategy

Level 1: Φ0.118mm

The second level: Φ0.1195mm

Grade 3: Φ0.120mm

Online compensation

Measure once every 100 pieces processed

Automatically compensate for tool wear

Real-time monitoring of SPC

Environmental control

Workshop constant temperature: 20±0.5℃

Cleanliness: 1000 grade

Foundation seismic resistance: Vibration < 2μm

"Outcome data"

Accuracy index

Hole diameter tolerance: ±0.0015mm (better than customer requirements)

Positional accuracy: 0.005mm

Batch consistency: Cpk > 2.0

Efficiency indicator

Single-piece processing time: 45 seconds

Daily production capacity: 1,500 pieces

The comprehensive efficiency of the equipment is 92%

Quality indicators

First-time pass rate: 99.8%

Customer return rate: 0%

Service life test: Exceeding the industry standard by 30%

Future technological layout

1. Ultra-precision processing technology

Target accuracy: ±0.0005mm

Nanoscale surface processing

Application of quantum measurement technology

2. Compound processing technology

Laser + mechanical processing composite

Ultrasonic vibration-assisted processing

Magnetic field-assisted processing

3. Green manufacturing technology

Dry processing technology

Tool life extension technology

Energy recycling and utilization

Technology inheritance and talent cultivation

Training system

Basic courses: Principles of Processing, Materials Science

Advanced courses: Numerical Control Programming, Process Optimization

Advanced courses: Technological Innovation, Project Management

Skill certification

Junior technician: Capable of operating equipment independently

Intermediate Technician: Capable of solving complex process problems

Senior Technician: Capable of technological innovation

Knowledge Management

Establish a process database

Experience case library

Technical standard system